Related Manuals for Fronius WF 25S
Summary of Contents for Fronius WF 25S
- Page 1 Operating Instructions WF 25s EN-US Operating instructions 42,0426,0503,EA 002-22042025...
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Page 3: Table Of Contents
Table of contents General Explanation of safety instructions Obligations of the Operating Company Obligations of Personnel Safety symbols Data backup Copyright Reading the available documents Utilization in accordance with "intended purpose" Intended use Foreseeable misuse Information about the device Device concept Notes on the device Warning notices on the device Description of the warnings on the device... - Page 4 Every 6 months Disposal Technical data Environmental conditions WF 25s HP 70s CON HP 95s CON...
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Page 5: General
General Explanation of DANGER! safety instruc- tions Indicates an immediate danger. Could result in major injury or death. ▶ Avoid the described danger. WARNING! Indicates a dangerous situation. Could result in serious injury or death. ▶ Avoid the dangerous situation. CAUTION! Indicates a harmful situation. -
Page 6: Safety Symbols
EN IEC 60974 Arc welding equipment and others The full text of the EU Declaration of Conformity is available at https://www.fronius.com Devices bearing the CSA label satisfy the requirements of the relevant standards for Canada and the USA. Data backup... - Page 7 QR code https://... Fortis 270 C - 500 C, Fortis 320 - 400 PDF manuals Find downloads: 42,0426,0498 The operating instructions can also be made available in printed form on request.
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Page 8: Utilization In Accordance With "Intended Purpose
Utilization in accordance with "intended purpose" Intended use The WF 25s wirefeeder is intended exclusively for MIG/MAG welding in combina- tion with Fronius system components. The wirefeeder is designed for welding operation during crane transport (e.g., on the crane boom, on the balancer, on movable mountings, etc.). -
Page 9: Information About The Device
Information about the device Device concept The WF 25s wirefeeder is equipped with a cover for wire spools with an external diameter of max. 300 mm (11.81 in.). The standard 4-roller drive offers excellent wire feeding properties. The wirefeeder is also suitable for long hosepacks. -
Page 10: Notes On The Device
Notes on the device Warning notices The wirefeeder has safety symbols and a rating plate fitted. These safety symbols on the device and the rating plate must not be removed or painted over. The safety symbols warn against operating the equipment incorrectly, as this may result in serious in- jury and damage to property. - Page 11 Keep hands, hair, loose clothing, and tools away from moving parts, such as: Gears Feed rollers Wire spools and wire electrodes Do not reach into rotating gears of the wire drive or into rotating drive parts. Covers and side panels must only be opened/removed during main- tenance and repair work.
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Page 12: Description Of The Warnings On The Device
Description of Warning notices are attached to the device for certain device versions. the warnings on the device The arrangement of the symbols may vary. Warning! Caution! The symbols represent possible dangers. Drive rollers can injure fingers. The welding wire and drive parts are under welding voltage during opera- tion. - Page 13 Use forced-air ventilation or local extraction to remove welding fumes. Remove welding fumes with a fan. Welding sparks can cause an explosion or fire. Keep flammable materials away from the welding process. Do not perform welding near flammable materials. Welding sparks can cause a fire. Have fire extinguishers ready. If neces- sary, have a supervisor ready who can operate the fire extinguisher.
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Page 14: Options
Options OPT/s WF con- The wirefeeder can be equipped with an optional control panel at the factory or trol unit have it retrofitted later. (13) (12) (11) (10) Description Welding process / operating mode button Left-hand selection dial: for selecting the welding process Right-hand selection dial: for selecting the operating mode Welding characteristic property / process function button Left-hand selection dial: for selecting the welding characteristic property... - Page 15 Current welding process line (in Duo operation) EXT = separate wirefeeder The display of the WF 25s always shows EXT; switching is not possible. Intermediate arc indicator Wire threading indicator lights up during wire threading if the wire threading graphic is hidden...
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Page 16: Opt/S Gas Test - Wire Inching
The parameters displayed vary according to the set welding process. (11) Multifunctional buttons The multifunctional buttons can be assigned EasyJobs. For details on EasyJobs, see from page onwards (12) Status bar 1 Contains information about: The currently selected welding process The currently selected operating mode The currently selected characteristic property Active process functions... -
Page 17: Further Options
For setting the required gas volume on the gas pressure regulator Tap button once: shielding gas flows out Tap button again: shielding gas flow stops If the button is not tapped again, the shielding gas flow will stop after 30 seconds. Press the button to the right –... -
Page 18: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components Front, rear, un- derside Function Crane bracket handle Control line connection socket For connecting the control line from the interconnecting hosepack (+) Current socket with bayonet latch For connecting the power cable from the interconnecting hosepack Shielding gas connection Coolant return connection (red) Option... -
Page 19: Wirefeeder Side
(10) Welding torch connection For connecting the welding torch (11) Swivel pin socket For placing the wirefeeder on the swivel pin of the swivel pin holder Wirefeeder side Function Wire spool holder For holding standard wire spools with a max. outer diameter of 300 mm (11.81 in.) and a max. -
Page 20: Before Installation And Initial Operation
Trabant on the TU Move 4 Pro trolley, with the welding system installed on the swivel pin holder WF 25s: Crane transport eyelets on the crane bracket handle... -
Page 21: Setup Regulations
When using a swivel pin holder, always ensure that the wirefeeder is firmly seated. The WF 25s wirefeeder has been tested according to protection class IP 23. This means: Protection against the penetration of solid foreign bodies with a diameter of more than 12.5 mm (0.49 in.) -
Page 22: Placing The Wirefeeder On The Swivel Pin Holder
Placing the wirefeeder on the swivel pin holder Placing the wirefeeder on the swivel pin holder... -
Page 23: Connecting The Wirefeeder To The Welding Machine
Connecting the wirefeeder to the welding ma- chine Connecting the The wirefeeder is connected to the welding machine by means of the intercon- wirefeeder to the necting hosepack. welding machine CAUTION! Danger from electric current due to defective system components. Personal injury and damage to property may result. - Page 24 Only if the coolant connections are installed in the wirefeeder and only if the interconnecting hosepack is water-cooled NOTE! Avoid damage when connecting the interconnecting hosepack! ▶ Route the cables and hoses in a loop inwards to the wirefeeder.
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Page 25: Inserting/Changing Feed Rollers
An overview of the available feed rollers and their possible uses can be found in the online spare parts catalog (O-ETK). Online spare parts catalog (O-ETK): https://spareparts.fronius.com CAUTION! Danger due to feed roller holders shooting upwards. This can result in personal injury. -
Page 28: Connecting The Welding Torch
Connecting the welding torch Connecting a Check that all cables, leads, and hosepacks are undamaged and correctly in- MIG/MAG weld- sulated ing torch to the wirefeeder Open the wire drive cover Open the clamping lever on the wire drive... - Page 29 Push the correctly equipped welding torch with the marking facing up from the front into the welding torch connection of the wirefeeder For water-cooled welding torches: Connect the coolant supply hose to the coolant supply connection (blue) Connect the coolant return hose to the coolant return connection (red) Close the clamping lever on the wire drive Close the wire drive cover Check that all connections are secure...
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Page 30: Inserting The Wirespool/Basket-Type Spool
Inserting the wirespool/basket-type spool Safety WARNING! Danger from electric current. This can result in serious personal injury and damage to property. ▶ Before carrying out maintenance or service work, switch off all devices and components involved and disconnect them from the power supply. ▶... - Page 31 CAUTION! Danger due to falling wire spool as a result of the locking ring being fitted the wrong way round. Could result in personal injury and functional impairments. ▶ Always position the locking ring as shown in the image below.
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Page 32: Installing The Basket-Type Spool
Installing the NOTE! basket-type spool When working with basket-type spools, only use the basket-type spool ad- apter supplied with the device. CAUTION! Danger from springiness of spooled wire electrode. Personal injury may result. ▶ Wear safety goggles. ▶ When inserting the wirespool/basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back. - Page 33 CAUTION! Danger due to falling basket-type spool as a result of the locking ring being fitted the wrong way round. Could result in personal injury and functional impairments. ▶ Always position the locking ring as shown in the image below.
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Page 35: Threading The Wire Electrode
Threading the Wire Electrode Feeding in the CAUTION! wire electrode Danger from springiness of spooled wire electrode. Personal injury may result. ▶ Wear safety goggles. ▶ When inserting the wirespool/basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back. - Page 36 NOTE! The wire electrode can be threaded by pressing a wire threading button provided in the welding system or by pressing the torch trigger. ▶ The "Wire threading" dialog window is shown on the displays of the welding machine and wirefeeder. Instructions for wire threading If contact is made with the ground during wire threading, the wire electrode is automatically stopped.
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Page 37: Setting The Contact Pressure
Setting the con- NOTE! tact pressure Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding. The standard values for the contact pressure can be found on the sticker on the 4-roller drive. -
Page 38: Adjusting The Brake
Adjusting the brake Adjusting the NOTE! brake After releasing the torch trigger, the wire spool must stop unreeling. Adjust the brake if necessary. STOP STOP... -
Page 39: Design Of The Brake
Design of the CAUTION! brake Danger from incorrect installation. Personal injury and damage to property may result. ▶ Do not dismantle the brake. ▶ Maintenance and servicing of brakes is to be carried out by trained, quali- fied personnel only. The brake is only available as a complete unit. -
Page 40: Commissioning
Commissioning Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be car- ried out by technically trained and qualified personnel. -
Page 41: Settings On The Optional Control Panel
Settings on the optional control panel Selecting the welding process and operating mode Press the welding process / operating mode button Turn the left-hand selection dial and select the desired welding process Press the left-hand selection dial to confirm the selection Turn the right-hand selection dial and select the desired operating mode Press the right-hand selection dial to confirm the selection Press the welding process / operating mode button to exit the menu... -
Page 42: Setting The Welding Characteristic Property And Process Function
Setting the Setting the welding characteristic property and the process functions is only rel- welding charac- evant for the Pulse and Standard welding processes. teristic property and process function Press the welding characteristic property / process functions button Turn the left-hand dial and select the desired welding characteristic property. NOTE! Filler metal, diameter of the wire electrode, and shielding gas can only be set on the welding machine! -
Page 43: Setting The Welding Parameters
Setting the welding para- meters The welding parameter is selected The value of the welding parameter can be changed The welding parameter symbol is high- The value of the welding parameter is lighted on the display between 2 blue highlighted on the display. lines. -
Page 44: Easyjobs
EasyJobs The 4 multifunctional buttons can be assigned EasyJobs. The EasyJobs can then simply be retrieved at the touch of a button. Saving an EasyJob NOTE! Up to four EasyJobs can be saved using the existing multifunctional buttons. The EasyJobs are stored under job numbers 1 - 4 and can also be retrieved via Job Mode. - Page 45 The EasyJob was deleted from the storage location.
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Page 46: Troubleshooting
Troubleshooting Troubleshooting Make a note of the serial number and configuration of the device, and provide the service team with a detailed error description if: Errors occur that are not covered in this document The troubleshooting measures provided in this document are unsuccessful Welding machine not working Power switch is switched on;... - Page 47 no shielding gas all other functions present Cause: Gas cylinder empty Remedy: Change gas cylinder Cause: Gas pressure regulator faulty Remedy: Replace gas pressure reducer Cause: Gas hose not attached, or damaged Remedy: Attach or replace gas hose Cause: Welding torch faulty Remedy: Change welding torch Cause:...
- Page 48 Poor-quality weld properties Cause: Incorrect welding parameters Remedy: Check settings Cause: Poor ground earth connection Remedy: Establish good contact with workpiece Cause: Too little or no shielding gas Remedy: Check gas pressure regulator, gas hose, gas solenoid valve, welding torch gas connection, etc. Cause: Welding torch leaks Remedy:...
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Page 49: Service, Maintenance And Disposal
Service, maintenance and disposal General The device only requires minimal of service and maintenance under normal oper- ating conditions. However, several points must be observed for the welding sys- tem to remain operational for years to come. Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. -
Page 50: Disposal
Open covers, dismantle device side panels, and blow the inside of the device clean with dry, reduced compressed air. After cleaning, restore the system to its original condition. Disposal Waste electrical and electronic equipment must be collected separately and re- cycled in an environmentally sound manner in accordance with the European Dir- ective and national law. -
Page 51: Technical Data
Relative humidity of ambient air: at 40 °C / 104 °F max. 50% at 20 °C / 68 °F max. 90% WF 25s Supply voltage 24 V DC / 42 V DC Nominal current 0.5 A / 1.5 A Welding current 40% ED* / 500 A at 10 min/40 °C (104 °F) -
Page 52: Hp 70S Con
HP 70s CON Length 1.2 / 5 / 10 / 15 / 20 m 3+11.2 / 16+4.9 / 32+9.7 / 49+2.6 / 65+7.4 ft + in. Welding current 40% ED* / 400 A at 10 min/40 °C (104 °F) 60% ED* / 365 A 100% ED* / 320 A ED = duty cycle HP 95s CON...
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